Method for preparing mattresses for shipment and stack of mattresses prepared using such method

ABSTRACT

An assembly of stacked mattresses and a method for preparing such an assembly are provided. The assembly of stacked mattresses comprises a first pallet, a second pallet, a plurality of mattresses positioned between the first pallet and the second pallet and straps coupling the first pallet to the second pallet, the plurality of mattresses being in a compressed state between the first pallet and the second pallet and the straps restraining expansion of the plurality of mattresses. The second pallet is comprised of a supporting member and a plurality of elongated reinforcing members extending across the supporting member, at least some of the reinforcing members including respective strap guiding members extending longitudinally along the elongated reinforcing member. At least some of the straps engage respective ones of the strap guiding members of the plurality of elongated reinforcing member of the second pallet so that displacement of the straps is constrained by the strap guiding members. In accordance with another aspect, a pallet for using in shipping bedding products is provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 16/267,734 filed Feb.5, 2019 (presently allowed), which itself was a continuation claimingpriority under 35 U.S.C. § 120 to U.S. patent application Ser. No.15/919,440 filed Mar. 13, 2018, which issued as U.S. Pat. No. 10,239,657on Mar. 26, 2019, which itself was a continuation claiming priorityunder 35 U.S.C. § 120 to U.S. patent application Ser. No. 15/394,536filed Dec. 29, 2016 which issued as U.S. Pat. No. 9,944,430 on Apr. 17,2018 which itself was a continuation claiming priority under 35 U.S.C. §120 to U.S. patent application Ser. No. 15/016,556 filed Feb. 5, 2016which issued as U.S. Pat. No. 9,555,923 on Jan. 31, 2017, which itselfwas a continuation claiming priority under 35 U.S.C. § 120 to U.S.patent application Ser. No. 14/230,927 filed Mar. 31, 2014 which issuedas U.S. Pat. No. 9,278,777 on Mar. 8, 2016. The contents of theaforementioned documents are incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to the packaging of mattresses forshipment, and more particularly, to the packaging of mattresses forshipment in containers using air, sea or ground transportation.

BACKGROUND

Large quantities of mattresses are imported from overseas into Canadaand the United States, in particular from China and other Asiancountries. The importation of large quantities of mattresses is drivenby the reality that manufacturers in China and other Asian countries areable to produce mattresses at a lower cost than manufacturers in NorthAmerica. When these mattresses are being transported, they are typicallypackaged and carried via ship in containers. There is a cost associatedwith the shipping, which is in part a function of the volume occupied bythe mattresses.

In view of reducing shipping costs, various methods have been used forpackaging mattresses for shipment to allow placing more mattresses in agiven container. As will be appreciated, if a larger number ofmattresses can be packaged within a given space, the shipping costsassociated with any individual mattress will be lower. One example of amethod of preparing mattresses for shipment is suggested in U.S. Pat.Nos. 7,458,093 and 7,895,813, the contents of which are incorporatedherein by reference. Generally speaking, the suggested approach includesfirst individually compressing and wrapping mattresses, for example, byvacuum sealing each individual mattress. Following this, a set ofindividually compressed mattresses is stacked between upper and lowershipping supports. The stack of mattresses is then further compressedbetween the supports, which are then fastened to one another usingcoupling restraints in the form of straps. Following this, the stackedmattresses with the upper and lower shipping supports can be placedwithin a container for shipping.

Approaches of the type described above advantageously may allow a largernumber of mattresses to fit within a given container and thus mayenhance transportation cost efficiency.

A deficiency associated with assemblies of stacked mattresses preparedusing methods of the type described above is that, on occasion thestraps and/or the shipping supports get damaged during transport orhandling due in part to the pressure exerted on these components by thecompressed stack of mattresses. When damage occurs, the result in somecases is that the compressed mattresses expand within the containersused for the shipment. This expansion within the containers often makesremoving the mattresses from such containers without damaging themattresses difficult. As a result, the cost savings achieved by packinga larger number of mattresses per container is reduced by the cost ofthe damaged mattresses, which often can no longer be sold to customers.

In light of the above, there is a need in the industry for providing animproved assembly of stacked mattresses and an improved method forpreparing such an assembly that alleviates, at least in part, thedeficiencies with existing assemblies and methods.

SUMMARY

In accordance with a first aspect, the invention relates to an assemblyof stacked mattresses comprising a first pallet, a second pallet, aplurality of mattresses positioned between the first pallet and thesecond pallet and straps coupling the first pallet to the second pallet.The plurality of mattresses is in a compressed state between the firstpallet and the second pallet and the straps restrain expansion of theplurality of mattresses. The second pallet is comprised of a supportingmember and a plurality of elongated reinforcing members extending acrossthe supporting member, at least some of the reinforcing membersincluding respective strap guiding members extending longitudinallyalong the elongated reinforcing member. At least some of the strapsengage respective ones of the strap guiding members of the plurality ofelongated reinforcing member of the second pallet.

In accordance with a first specific example of implementation, at leastsome of the strap guiding members are comprised of hollow tubularportions extending longitudinally along the elongated reinforcingmembers of the second pallet and at least some of the straps passthrough at least some of the hollow tubular portions.

In accordance with a second specific example of implementation, at leastsome of the strap guiding members are comprised of U-shaped portionsextending longitudinally along the elongated reinforcing members of thesecond pallet and wherein the at least some of the straps are positionedwithin at least some of the U-shaped portions, the U-shaped portionsrestraining movement of the at least some straps relative to thesupporting member of the second pallet.

In accordance with another alternative specific example ofimplementation, at least some of the strap guiding members extendlongitudinally along the elongated reinforcing members of the secondpallet and are comprised of a combination of hollow tubular portions andU-shaped portions positioned end-to-end.

In specific practical implementations, the strap guiding members may bemade, for example, of a metallic material and/or a plastic material. Thesupporting member of the second pallet may be made at least in part of awood-based material, such as for example a medium-density fiberboard(MDF) or a plywood material. The straps used to couple the first palletto the second pallet may be made of any suitable material such as forexample nylon, polypropylene and synthetic steel composite.Advantageously, it has been found that, in some cases, straps made ofsynthetic steel composite tend to be less affected by temperaturevariations, and in particular tend to be less affect by coldtemperatures, than similarly sized nylon straps which may render suchstraps more durable and less likely to break that nylon straps.

In specific practical implementations, the supporting member of thesecond pallet has a surface area substantially similar to a surface areaof an individual mattress in the plurality of mattresses. Innon-limiting implementations, the supporting member of the second palletmay have a substantially rectangular shape.

In specific implementations, the plurality of mattresses may include anysuitable number of mattresses. The number of mattresses in practicalimplementations may generally be selected based upon the number ofmattresses that, when compressed between the two pallets, can reasonablyfit within the specific container that is to be used for the shipment.

In a specific implementation, the first pallet has a configurationsimilar to that of the second pallet and is comprised of:

-   -   i) a supporting member; and    -   ii) a plurality of elongated reinforcing members extending        across the supporting member, at least some of the elongated        reinforcing members including respective strap guiding members        extending longitudinally along the elongated reinforcing        members.

In the assembly, at least some straps engage respective ones of thestrap guiding members of the plurality of elongated reinforcing membersof the first pallet.

In accordance with another aspect, the invention relates to a pallet foruse in shipping bedding products. The pallet comprises a supportingmember and a plurality of elongated reinforcing members extending acrossthe supporting member. At least some of the elongated reinforcingmembers include respective strap guiding members extendinglongitudinally along the elongated reinforcing members.

In accordance with a first specific implementation, at least some of thestrap guiding members are comprised of hollow tubular portions extendinglongitudinally along the elongated reinforcing members, the hollowtubular portions being adapted for receiving therethrough straps.

In accordance with a second specific implementation, at least some ofthe strap guiding members are comprised of U-shaped portions extendinglongitudinally along the elongated reinforcing members. The U-shapedportions are configured to receive therein straps and for restrainingmovement of straps positioned therein.

In specific practical implementations, the strap guiding members may bemade, for example, of a metallic material or a plastic material. Thesupporting member of the second pallet may be made at least in part of awood-based material, such as for example a medium-density fiberboard(MDF) or a plywood material. The straps used to couple the first palletto the second pallet may be made of any suitable material such as forexample nylon, polypropylene and synthetic steel composite.

In accordance with another aspect, the invention relates to the use of apallet of the type described above for shipping bedding products, suchas for example mattresses, pillows and the like.

In accordance with another aspect, the invention relates to a method forpreparing mattresses for shipment. The method comprises providing afirst pallet and a second pallet. The second pallet is comprised of asupporting member and of a plurality of elongated reinforcing membersextending across the supporting member, at least some of the elongatedreinforcing members including respective strap guiding members extendinglongitudinally along the elongated reinforcing members. The methodfurther comprises placing a plurality of mattresses on a surface of oneof the first pallet and the second pallet and placing the other one ofthe first pallet and the second pallet on top of the plurality ofmattresses. The method also comprises compressing the plurality ofmattresses between the first pallet and the second pallet and couplingthe first pallet to the second pallet using straps, the strapsrestraining expansion of the compressed plurality of mattresses. Atleast some of the straps engage respective ones of the strap guidingmembers of the plurality of elongated reinforcing members of the secondpallet.

In accordance with a first specific example of implementation, at leastsome of the strap guiding members are comprised of hollow tubularportions extending longitudinally along the elongated reinforcingmembers. In the method, the step of coupling the first pallet to thesecond pallet includes passing at least some of the straps through atleast some of the hollow tubular portions.

In accordance with a second specific example of implementation, at leastsome of the strap guiding members are comprised of U-shaped portionsextending longitudinally along the elongated reinforcing members. In themethod, the step of coupling the first pallet to the second palletincludes positioning at least some of the straps within at least some ofthe U-shaped portions. In some implementations, the U-shaped portionsmay restrain movement of the at least some straps relative to thesupporting member of the second pallet.

In a specific practical implementation, the supporting member of thesecond pallet has a surface area substantially similar to a surface areaof an individual mattress in the plurality of mattresses.

In specific implementations, the plurality of mattresses may include anysuitable number of mattresses. The number of mattresses in practicalimplementations may generally be selected based upon the number ofmattresses that, when compressed between the two pallets, can reasonablyfit within the specific container that is to be used for the shipment.Practical implementations may include placing two or more mattressesupon the first pallet.

In a specific implementation, the method further comprising compressingindividually the mattresses in the plurality of mattresses prior toplacing the plurality of mattresses on the first pallet.

In a specific implementation, the first pallet has a configurationsimilar to that of the second pallet and is comprised of:

-   -   i) a supporting member; and    -   ii) a plurality of elongated reinforcing members extending        across the supporting member, at least some of the elongated        reinforcing members including respective strap guiding members        extending longitudinally along the elongated reinforcing        members.

In this specific implementation, coupling the first pallet to the secondpallet may further include engaging at least some of the straps withrespective ones of the strap guiding members of the plurality ofelongated reinforcing members of the first pallet.

In accordance with another aspect, the invention relates to an assemblyof stacked mattresses prepared for shipment in accordance with a methodof the type defined above.

In accordance with another aspect, the inventions relates to an assemblyof stacked mattresses. The assembly comprises a first pallet, a secondpallet, a plurality of mattresses positioned between the first palletand the second pallet and straps coupling the first pallet to the secondpallet. The plurality of mattresses is in a compressed state between thefirst pallet and the second pallet and the straps restrain expansion ofthe plurality of mattresses. The second pallet is comprised of asupporting member and of a plurality of elongated grove membersextending across the supporting member. At least some of the strapsengage respective ones of the elongated grove members of the secondpallet.

These and other aspects of the invention will now become apparent tothose of ordinary skill in the art upon review of the followingdescription of embodiments of the invention in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of embodiments of the invention is providedbelow, by way of example only, with reference to the accompanyingdrawings, in which:

FIG. 1 shows an assembly of stacked mattresses in accordance with aspecific example of implementation of the invention.

FIGS. 2A and 2B are perspective views of a pallet suitable for use in anassembly of the type shown in FIG. 1 in accordance with a firstembodiment of the invention.

FIGS. 2C and 2D are perspective views of a pallet suitable for use in anassembly of the type shown in FIG. 1 in accordance with a secondembodiment of the invention.

FIGS. 2E and 2F are perspective views of a pallet suitable for use in anassembly of the type shown in FIG. 1 in accordance with a thirdembodiment of the invention.

FIG. 3 is perspective views of a variant of the pallet depicted in FIGS.2A and 2B.

FIG. 4 is a flowchart of a method for preparing an assembly ofmattresses of the type depicted in FIG. 1 in accordance with a specificexample of implementation of the invention;

FIG. 5 is a perspective view of a first pallet on which a plurality ofmattresses has been stacked in accordance with a specific example ofimplementation of the invention.

FIG. 6 is a perspective view of the first pallet of FIG. 5, on which aplurality of mattresses has been stacked, where a second pallet is beingplaced on top of the plurality of mattresses in accordance with aspecific example of implementation of the invention.

FIG. 7 is a variant of FIG. 6 in which protective material has been usedto protect the mattresses.

FIG. 8A shows a plurality of mattresses positioned between a firstpallet and a second pallet prior to being placed within a press forcompressing the plurality of mattresses in accordance with an embodimentof the present invention.

FIG. 8B shows the plurality of mattresses of FIG. 8A positioned withinthe press.

FIG. 8C shows the plurality of mattresses of FIG. 8A being compressed bythe press.

FIG. 8D shows the plurality of mattresses of FIG. 8A wherein the firstand second pallets are being coupled to one another using straps.

FIG. 8E shows the plurality of mattresses of FIGS. 8A-8D being removedfrom the press after the step depicted in FIG. 8D.

FIG. 9 shows a coupling device fastening a strap used for coupling thepallets of an assembly of mattresses of the type depicted in FIG. 1 inaccordance with a specific embodiment of the present invention.

FIG. 10 shows an assembly of stacked mattresses in accordance with avariant of the invention.

In the drawings, embodiments of the invention are illustrated by way ofexample. It is to be expressly understood that the description anddrawings are only for the purpose of illustrating certain embodiments ofthe invention and are an aid for understanding. They are not intended tobe a definition of the limits of the invention.

DETAILED DESCRIPTION

FIG. 1 shows a specific non-limiting example of an assembly of stackedmattresses. As shown, the assembly 790 includes a first pallet 401, asecond pallet 501 and a plurality of mattresses 302 positioned betweenthe first pallet 401 and the second pallet 501. In this example, thefirst pallet 401 is a lower pallet and the second pallet 501 is an upperpallet.

The plurality of mattresses 302 is arranged in a stack atop the firstpallet 401 and the second pallet 501 is positioned on top of theplurality of mattresses 302. The assembly 790 also includes straps 510coupling the first pallet 401 to the second pallet 501. In a specificimplementation, the plurality of mattresses 302 is in a compressed statebetween the first pallet 401 and the second pallet 501 and the straps510 restrain the expansion of the plurality of mattresses 302. In theexample depicted, an optional protective cover 908 shields the pluralityof stacked mattresses from outside elements. The optional protectivecover 908 may be made of any suitable material which may include,without being limited to corrugated cardboard, packaging paper, plasticwrapping and/or a woven nylon protective material.

In the example depicted, the upper (or second) pallet 501 includes asupporting member 502 and a plurality of elongated reinforcing members503 extending across the supporting member 502. The reinforcing members503 include respective strap guiding members 504 extendinglongitudinally along the elongated reinforcing member 503. The straps510 engage respective ones of the strap guiding members 504 as theycouple together the first and second pallets 401 501. Advantageously,the elongated strap guiding members 504 may restrain movement of thestraps 510 relative to the supporting member 502 and in that manner mayreduce the amount of wear endured by the straps, which in turn mayreduce the likelihood the straps will break. In this specific example,the elongated strap guiding members 504 include hollow tubular portionsextending longitudinally along the elongated reinforcing members 503.The hollow tubular portions accommodate the straps 510, which passthrough the hollow tubular portions.

In another example, not show in FIG. 1, the elongated strap guidingmembers may include U-shaped portions extending longitudinally along theelongated reinforcing members. The U-shaped portions are configured toaccommodate the straps 510, which would be positioned within theU-shaped portions, the U-shaped portions restraining the lateralmovement of at least some straps relative to the supporting member. Itis to be appreciated that the elongated strap guiding members 504 may beotherwise configured to restrain movement of the straps 510 relative tothe supporting member 502 and such alternatives will become apparent tothe person skilled in the art in light of the present document.

In yet another example of implementation, not show in FIG. 1, instead ofreinforcing members 503, the pallet may include a supporting member anda plurality of elongated grove members formed on a surface of thesupporting member and extending across it. The grove members are shapedto accommodate the straps, which would be positioned within the grovemembers, and restrain the lateral movement of at least some strapsrelative to the supporting member.

In the specific example depicted, the lower (or first) pallet 401, isconfigured in a manner similar to the upper (or second) pallet 501 andincludes a supporting member 402 and a plurality of elongatedreinforcing members 403 extending across the supporting member 402. Thereinforcing members 403 include respective strap guiding members 404extending longitudinally along the elongated reinforcing member 403.

The straps 510 engage respective ones of the strap guiding members 404and strap guiding members 504 as they couple the first and secondpallets 401 501 with one another. The straps 510 may be made of anysuitable material such as nylon, polypropylene, synthetic steelcomposite or any other suitable material. In some embodiments, thestraps 510 may be steel bands. In the example depicted, the ends of thestrap 510 are coupled together with respective coupling devices 810.

In the example depicted, optional protective strips 910 positioned onthe sides of the stack of compressed mattresses 302 may be provided.These protective strips 910 are generally aligned with the straps 510extending between the first and second pallets 501 401. Morespecifically, in some embodiments, the protective strips may bepositioned to be generally aligned with the strap guiding members 404and strap guiding members 504. Moreover, in some embodiments, theprotective strips 910 may be placed on top of the protective cover 908,while in other embodiments the protective cover 908 may overlay theprotective strips 910. The optional protective strips 910 may be made ofany suitable material which may include, without being limited topolyurethane foam or felt padding. The use of protective strips 910 mayadvantageously reduce friction between the straps 510 and the stackedmattresses 302 and hence reduce the likelihood the straps will damagethe mattresses during transport.

FIGS. 2A and 2B are perspective views showing a configuration of apallet 201 that may be used for the first pallet 401, the second pallet501 or both the first and second pallets 401 501 of an assembly ofstacked mattresses of the type shown in FIG. 1 in accordance with afirst embodiment of the invention.

FIG. 2A shows a perspective view of a first surface 207 of the pallet201 and FIG. 2B shows a perspective view of a second surface 206 of thepallet 201.

As depicted, the pallet 201 includes a supporting member 202 and aplurality of elongated reinforcing members 203 (where 203 _(x), denote aspecific elongated reinforcing member from the plurality of elongatedreinforcing members 203) extending across the supporting member 202. Inthis example, the supporting member 202 has a first surface 207 and asecond surface 206 and the plurality of elongated reinforcing members203 are attached to the first surface 207 of the supporting member 202.In FIGS. 2A and 2B five elongated reinforcing members 203 _(a), 203_(b), 203 _(c), 203 _(d), and 203 _(e) are shown; however, it is to beappreciated that the number of reinforcing members on a pallet may bemore or less than five in alternative implementations of the invention.In practical implementations, a pallet having two or more elongatedreinforcing members will be preferred.

The supporting member 202 may be made, for example, at least in part ofwood, plastic, metal, and/or any other suitable material. Morespecifically, in some embodiments, the supporting member 202 may be madeat least in part of wood-based materials which may include one or morewooden planks, plywood planks, boards and the like. The supportingmember 202 may have a surface area that is substantially similar to asurface area of an individual mattress 301 in the stack of mattresses302 in order to distribute the pressure exerted by the compressedmattresses over the surface of the supporting member 202. In specificpractical implementations, the supporting member 202 may have asubstantially rectangular shape generally corresponding to the shapedthe mattresses being shipped. In specific practical implementations, thesupporting member 202 may be a single sheet of plywood or a single sheetof medium-density fiberboard (MDF) that has dimensions (length andwidth) substantially similar to the dimensions of the mattress 301. Inimplementations in which the supporting member 202 is a single sheet ofplywood or medium density fiberboard, the single sheet of plywood ormedium density fiberboard may have any suitable thickness. Innon-limiting implementations, a sheet of plywood having a thickness inthe range of ¼ inch to 2 inches may be used. It is noted that thereinforcing members 204 increase the tensile strength of such a sheet ofplywood and therefore permit a sheet of plywood of a lesser thickness tobe used without compromising the solidity of the pallet 201.

As shown in FIG. 2A, the pallet 201 includes a plurality of elongatedreinforcing members 203 extending across the supporting member 202. Theelongated reinforcing members 203 may be made of wood, plastic, metal,and/or any other suitable material. The elongated reinforcing members203 may be positioned alongside one another in a spaced-apartrelationship over the surface 207 of the supporting member 202 in themanner depicted in FIG. 2A for example.

At least some of the elongated reinforcing members 203 includerespective strap guiding members 204 extending longitudinally along theelongated reinforcing member 203. While all the reinforcement membersshown in FIG. 2A include strap guiding members 204, it is to beappreciated that in alternative embodiment only some reinforcing member203 may include strap guiding members 204. As such, the number of strapguiding members 204 need not be the same as the number of reinforcingmembers 203. In the embodiment illustrated in FIGS. 2A and 2B, fivestrap guiding members 204 _(a), 204 _(b), 204 _(c), 204 _(d), and 204_(e) are shown; however, it is to be appreciated that the number ofstrap guiding members may be more or less than five in alternativeimplementations of the invention. In practical implementations, a pallethaving two or more strap guiding members will be preferred.

The strap guiding members 204 may be configured to receive and guide oneor more straps 510 (not shown in FIGS. 2A and 2B—shown in FIG. 1) overthe surface 207 of the supporting member. At least some of the straps510 engage respective ones of the strap guiding members 204 of theplurality of elongated reinforcing member 203 of the pallet 201. Inother words, the strap guiding members 204 may be configured to receiveand guide one or more straps 510 longitudinally along the reinforcingmembers 203. In the embodiment depicted in FIGS. 2A and 2B, the strapguiding members 204 are comprised of hollow tubular portions extendinglongitudinally along the reinforcing members 203. In the cases where thestrap guiding members 204 comprises hollow tubular portions, at leastsome of the straps 510 pass through at least some of the hollow tubularportions.

The hollow tubular portions may be of a generally square, rectangular,semi-circular cross-sectional shape or of any other suitable shape. Forexample, the strap guiding members 204 may be A500 grade steelstructural square tubes having a height of 2 inches, width of 2 inchesand a wall thickness of ⅛ of an inch. However, the dimensions of thestrap guiding members 204 are not limited to the example given above andany suitable dimension and cross-section may be used. By way of anexample, the strap guiding members 204 may be made at least in part ofmetal, plastic or wood square or rectangular tubes having a height inthe range of ½ an inch to 4 inches, a width in the range of in the rangeof ½ an inch to 4 inches and a wall thickness in the range of 0.065 ofan inch to ½ an inch.

The elongated reinforcing members 203 may be fastened to the surface 207of supporting member 202 using any suitable fastener or any suitablebinding material. For example, the plurality of elongated reinforcingmembers 203 may be fastened to the supporting member 202 by one or morescrews, nails, tacks, brackets or any other suitable mechanicalfastener. In alternative embodiments, the reinforcing members 203 may bebound to the supporting member 202 using a glue, an adhesive or anysuitable chemical binder. In the non-limiting embodiment depicted inFIGS. 2A and 2B, the reinforcing members 203 includes interface members205 for fastening to the supporting member 202. The interface members205 may be positioned between the strap guiding members 204 and thesupporting member 202 and may facilitate the fastening or binding of thereinforcing members 203 to the supporting member 202 during assembly ofthe pallet 201. The one or more interface members 205 may be comprisedof elongated strips of plastic, wood, metal, and/or any other suitablematerial.

FIG. 3 shows a pallet 201″, which is a variant of pallet 201 shown inFIGS. 2A and 2B, in which the elongated reinforcing members 203″ arefastened to the surface 207 of supporting member 202 using a set ofbrackets or braces 222 positioned at different locations along thelength of the respective elongated reinforcing members 203″. Thebrackets or braces 222 may be made of any suitable material, such asmetal, steel or nylon strapping.

FIGS. 2C and 2D are perspective views of another configuration of apallet 201′ that may be used for the first pallet 401, the second pallet501 or both the first and second pallets 401 and of an assembly of thetype shown in FIG. 1 in accordance with a second embodiment of theinvention. In this alternative configuration, the pallet 201′ has somecomponents similar to the components of pallet 201 shows in FIGS. 2A and2B. For ease of understanding, the components that are common to the twoconfigurations have been given the same reference numerals.

As depicted, the pallet 201′ includes a supporting member 202 and aplurality of elongated reinforcing members 203′ extending across thesupporting member 202. In this example, the supporting member 202 has afirst surface 207 and a second surface 206 and the plurality ofelongated reinforcing members 203′ are attached to the first surface 207of the supporting member 202. As shown in FIG. 2C, the pallet 201′includes a plurality of elongated reinforcing members 203′ extendingacross the supporting member 202. The elongated reinforcing members 203′may be made of wood, plastic, metal, and/or any other suitable materialand may be fastened to the supporting member 202 in a manner similar tothe fastening of elongated reinforcing members 203 described withreference to the embodiment of FIGS. 2A and 2B. The elongatedreinforcing members 203′ may be positioned alongside one another in aspaced-apart relationship over the surface 207 of the supporting member202. In FIGS. 2C and 2D five elongated reinforcing members 203′_(a),203′_(b), 203′_(c), 203′_(d), and 203′_(e) are shown; however, it is tobe appreciated that the number of reinforcing members on a pallet may bemore or less than five in alternative implementations of the invention.In practical implementations, a pallet having two or more elongatedreinforcing members will be preferred.

At least some of the elongated reinforcing members 203′ includerespective strap guiding members 204′ extending longitudinally along theelongated reinforcing member 203′. While all the reinforcement membersshown in the figure including strap guiding members 204′, it is to beappreciated that in alternative embodiment only some reinforcing member203′ may include strap guiding members 204′. As such, the number ofstrap guiding members 204′ need not be the same as the number ofreinforcing members 203′.

The strap guiding members 204′ may be configured to receive and guideone or more straps 510 (not shown in FIGS. 2C and 2D—shown in FIG. 1)over the surface 207 of the supporting member 202. At least some of thestraps 510 engage respective ones of the strap guiding members 204′ ofthe plurality of elongated reinforcing member 203′ of the pallet 201. Inother words, the strap guiding members 204′ may be configured to receiveand guide one or more straps 510 longitudinally along the reinforcingmembers 203′.

In this embodiment, at least some of the strap guiding members 204′ arecomprised of U-shaped portions extending longitudinally along thereinforcing members 203′. The U-shaped portions are configured forreceiving therein one or more straps 510 (not shown in FIGS. 2C and 2D).The U-shaped portions may be of a generally triangular, square,rectangular or semi-circular cross-sectional shape having an openingforming a channel for receiving therein one or more straps. The strapguiding members 204′ may be made of any suitable material includingmetal, plastic or wood and may be of any suitable dimension forreceiving therein one or more straps. In a specific implementation, theU-shaped channels may have a width in the range of ½ an inch to 4inches, a leg or flange height in the range of in the range of ½ an inchto 4 inches and a wall or web thickness in the range of an ⅛ of an inchto ½ an inch.

Although in FIGS. 2A to 2D the elongated reinforcing members 203 203′have been illustrated as unitary components that traverse the supportingmember 202, it will be appreciated that this need not be the case in allembodiments. For example, each reinforcing members 203 203′ may beformed by multiple (2 or more) elongated reinforcing member segmentsarranged substantially end to end to traverse the surface of supportingmember 202.

In addition, while the embodiments depicted in FIGS. 2A, 2B, 2C and 2Dshow the strap guiding members 204 204′ as being either hollow tubularportions or U-shaped portions, it is to be appreciated that, in otheralternative implementations (not shown in the Figures), at least some ofthe strap guiding members may be comprised of a combination of hollowtubular portions and U-shaped portions positioned end-to-end across thesurface of the supporting member. In such an alternative configurations,the hollow tubular portions of the strap guiding members may preventstraps engaged in the strap guiding members from being displaced.

FIGS. 2E and 2F are perspective views of a variant of the pallets shownin FIGS. 2A, 2B, 2C and 2D and which may be used for the first pallet401, the second pallet 501 or both the first and second pallets 401 andof an assembly of the type shown in FIG. 1 in accordance with a thirdembodiment of the invention. In this alternative configuration, theplurality of reinforcing members 203 203′ including strap guidingmembers 204 204′ are replaced by a plurality of elongated grove members2003. More specifically, as depicted, the pallet 2001 includes asupporting member 2002 in which a plurality of elongated grove members2003 extending across the supporting member 2002 have be defined. Inthis example, the supporting member 2002 has a first surface 2007 and asecond surface 2006 and the plurality of elongated grove members 2003are formed on the first surface 2007 of the supporting member 2002. Asshown in FIG. 2E, the pallet 2001 includes a plurality of elongatedgrove members 2003 extending across the supporting member 2002. Theelongated grove members 2003 may be positioned alongside one another ina spaced-apart relationship over the surface 2007 of the supportingmember 2002. In FIGS. 2E and 2D five elongated grove members 2003 _(a),2003 _(b), 2003 _(c), 2003 _(d), and 2003 _(e) are shown; however, it isto be appreciated that the number of grove members on a pallet may bemore or less than five in alternative implementations of the invention.In practical implementations, a pallet having two or more elongatedgrove members will be preferred.

The elongated grove members 2003 are configured for receiving andguiding one or more straps 510 (not shown in FIGS. 2D and 2E) over thesurface 2007 of the supporting member 2002. At least some of the strapsengage respective ones of the elongated grove members 2003 of the pallet2001. In other words, the elongated grove members 2003 may be configuredto receive and guide one or more straps 510 longitudinally along thereinforcing members 2003.

In this embodiment, at least some of the elongated grove members 2003are formed as U-shaped portions extending longitudinally along thereinforcing members 2003. The U-shaped portions are configured forreceiving therein one or more straps (not shown in FIGS. 2C and 2D). TheU-shaped portions may be of a generally triangular, square, rectangularor semi-circular cross-sectional shape having an opening forming achannel for receiving therein one or more straps. The elongated grovemembers 2003 may be formed directly on the surface of the supportingmember 2002 by using any suitable machining technique and may be of anysuitable dimension for receiving therein one or more straps.

In a specific implementation, the supporting member 2002 may be made ofmay be made, for example, at least in part of wood, plastic, metal,and/or any other suitable material and the elongated grove members 2003are formed within the surface of the supporting member 2002. In aspecific implementation, the U-shaped channels may have a width in therange of ½ an inch to 6 inches and a leg or flange height in the rangeof in the range of ½ an inch to 2 inches. It is noted that the leg orflange height will depending on the thickness of the supporting member2002. Optionally, portions of the elongated grove members 2003 may becovered (not shown in the figures) to prevent straps engaged in thegrove members 2003 from being displaced once the assembly of mattressesis formed.

Returning now to the embodiment depicted in FIG. 1, the first pallet 401and/or the second pallet 501 may be constructed or may comprise any ofthe embodiments discussed above regarding the pallet 201, 201′, 2001and/or 201″ described with reference to FIGS. 2A, 2B, 2C, 2D, 2E and 2Fand 3. It is to be appreciated that, in practical implementations, thefirst pallet 401 and the second pallet 501 need not be identical to eachother. For instance, the first pallet 401 may be made according to theembodiment depicted in FIGS. 2A and 2B and the second pallet 501 may bemade according to the embodiment depicted in FIGS. 2C and 2D.Furthermore, as can be seen from the discussion above, the first pallet401 and the second pallet 501 may be made of wood, plastic, metal, othersuitable materials and/or any combination of these aforementionedmaterials. Alternatively still, the first pallet 401 or the secondpallet 501 may be a standard shipping pallet or skid of the type knownin the art, for example of the type described ISO Standard 6780: “Flatpallets for intercontinental materials handling—Principal dimensions andtolerances”, while the other pallet may be made according to one theembodiments described previously with reference to FIGS. 2A, 2B, 2C, 2D,2E, 2F and 3.

FIG. 4 is a flowchart showing a method 100 that may be used forpreparing an assembly of stacked mattresses of the type depicted in FIG.1.

As shown, at step 101, a first pallet 401 and a second pallet 501 areprovided. Next at step 102, mattresses are stacked upon the first pallet401. Then, at step 103 the second pallet 501 is placed on top of theplurality of stacked the mattresses. At step 104 the mattresses betweenthe first pallet 401 and the second pallet 501 are compresses to reducethe height of the stack of mattresses. Then, at step 105, the firstpallet 401 and the second pallet 501 are coupled together to restrainexpansion of the compressed mattresses 302. The coupling of the firstpallet 401 to the second pallet 501 may be done using any suitablemechanism such as for example by using straps 510. Once the first pallet401 and the second pallet 501 are coupled together, the assembly ofmattresses 790 may be placed within a container (not shown) and may betransported to a desired destination, via rail, ship or truck forexample. Each of the steps of the method 100 will now be discussed inmore detail with reference to FIGS. 5, 6, 7 and 8A to 8E.

At step 101, a first pallet 401 and a second pallet 501 are provided.The first pallet 401 and/or the second pallet 501 may be constructedaccording to any of the embodiments discussed above regarding the pallet201, 201′, and/or 201″. For the purpose of the present example, theprocess described will consider that both the first pallet 401 and thesecond pallet 501 are constructed in the manner described with referenceto pallet 201 described with reference to FIGS. 2A and 2B.

At step 102 of the method 100, mattresses are stacked on the firstpallet 401, which is illustrated in the perspective view shown in FIG.5. In this specific embodiment, the first pallet 401 is a lower palletand several individual mattresses 301 are placed on the first pallet 401to form a stack of mattresses 302. Optionally, each of the individualmattresses 301 may have been previously compressed prior to being placedupon the first pallet 401. For example, the compression of theindividual mattress 301 prior to stacking on the first pallet 401 mayfollow the suggested approach described in U.S. Pat. Nos. 7,458,093 and7,895,813.

Following this, at step 103 of the method 100, a second pallet 501 isplaced upon the stack of mattresses 302, which is illustrated in theperspective view shown in FIG. 6. In this example, the second pallet 501is shown with straps 510 having been passed through the respective strapguiding members 504.

Optionally, protective materials may be used to protect the mattressesfrom the first pallet 401 and/or the second pallet 501. This variant isillustrated in the perspective view shown in FIG. 7. As shown,protective materials 604 and/or 608 are placed on top of and below thestack of mattresses 302 to protect the mattresses from the first andsecond pallets 401 501. In this example, the upward facing surface ofthe first pallet 401 is covered with a protective material 604, such as,but not limited to corrugated cardboard, packaging paper, plasticwrapping and/or any other suitable material. Similarly, the top of theplurality of mattresses 302 is also covered with a protective material608, such as, but not limited to corrugated cardboard, packaging paper,plastic wrapping and/or any other suitable material.

Optionally still, not shown in FIGS. 6 and 7, protective strips 910(shown in FIG. 1) and/or a protective cover 908 (also shown in FIG. 1)may also be added to protect the stack of mattresses 302.

For example, a protective cover 908, such as a protective sheath, may beused to cover the periphery of the stack of mattresses 302. Theprotective cover 908 may be wrapped around the sides of the stack ofmattresses 302 and between the upper or second pallet 501 and the loweror first pallet 401. Such protective sheath may be made of any suitablematerial such as corrugated cardboard, packaging paper, plastic wrappingand/or any other suitable material, to further protect the mattresses.The protective cover 908 may be made of the same material as theprotective material 604 and 608 used to protect the top and bottom ofthe stack of mattresses 302 from the respective second pallet 501 andfirst pallet 401 or may be a different material.

Optional protective strips 910 may be positioned on the sides of thestack of compressed mattresses 302. The optional protective strips 910may be made of any suitable material which may include, without beinglimited to, polyurethane foam or felt padding. The protective strips 910may be positioned generally along the sides of the stack of mattresses302 between the upper or second pallet 501 and the lower or first pallet401. More specifically, in some embodiments, the protective strips maybe positioned to be generally aligned with the strap guiding members 404and strap guiding members 504. Moreover, in some embodiments, theprotective strips 910 may be paced on top of the protective cover 908,while in other embodiments the protective cover 908 may overlay theprotective strips 910. (For examples of embodiments illustrating theprotective strips 910 and protective cover 908 see FIGS. 1 and 10).

After the second pallet 501 has been placed upon the stack of mattresses302, the process proceeds to step 104.

At step 104 of the method 100, the stack of mattresses 302 between thefirst pallet 401 and the second pallet 501 is compresses in order toreduce the height of the stack of mattresses. FIGS. 8A to 8E illustratean example, in accordance with a non-limiting embodiment of the presentinvention, of a process for compressing the stack of mattresses 302 anda device for effecting such compressing. For the purpose of simplifyingthe description, in FIGS. 8A to 8E the combination including the stackof mattresses 302, the first pallet 401 and the second pallet 501 willbe designated as a group as assembly 700.

FIGS. 8A and 8B illustrate, in accordance with an embodiment of thepresent invention, placing the assembly 700 within a press 705,possibly, but not limited to, a hydraulic press employing a verticalhydraulic press plate 707. The press 705 comprises a sensor 715 that iscoupled to a controller 720 and that detects the position of the pressplate 707 when the mattress stack 302 has been squeezed to apredetermined set height 770. The controller 720 is coupled to at leastone hydraulic actuator 727, coupled to the press plate 707 and capableof raising and lowering the press play 707.

FIG. 8C illustrates, in accordance with an embodiment of the presentinvention, lowering the press plate 707 and compressing the stack ofmattresses 302 to the stack predetermined-set height 770. As the pressplate 707 is lowered, an opening 710 between the press plate 707 and afloor 750 is reduced, thereby compressing the stack of mattresses 302resting upon the lower of first pallet 401, which, in turn, rests uponthe floor 750, to the stack predetermined-set height 770. When the pressplate 707 reaches a position 770 corresponding to the height of thestack of mattresses 302 reaching the stack predetermined-set height 780and resulting in a compressed assembly of mattresses 790, a signal fromthe position sensor 715 to the controller 720 results in a halt tovertical movement of the press plate 707. FIG. 8C also illustrates, inaccordance with an embodiment of the present invention, locking thepress plate 707 in position and passing one or more straps 510 througheach of the strap guiding members 404 of the first pallet 401 andthrough each of the strap guiding members 504 of the second pallet 501.FIG. 8C also shows at least some of the straps 510 engaging respectiveones of the strap guiding members 504 of the plurality of elongatedreinforcing member 503 of the second pallet 501. FIG. 8C also shows atleast some of the straps 510 engaging respective ones of the strapguiding members 404 of the plurality of elongated reinforcing member 403of the first pallet 401.

After the assembly 700 has been compressed, the process proceeds to step105.

At step 105 of the method 100, the first pallet 401 and the secondpallet 501 are coupled together to restrain expansion of the pluralityof mattresses and to maintain the stack of mattresses 302 in acompressed state and at substantially the stack predetermined set height770. FIG. 8D illustrates, in accordance with an embodiment of thepresent invention, the first and second pallets 401 501 being coupledtogether using a plurality of straps 510.

In the specific example shown in the Figures, for each of the strapguiding members 503 on the second pallet 501 there is a correspondingstrap guiding members 403 on the first pallet 401 in which at least oneof the straps 510 passes through. In accordance with a specific andnon-limiting example, in the case where the first pallet member 401 hasstrap guiding members 404 _(a), 404 _(b), . . . and 404 _(e) and thesecond pallet member 501 has strap guiding members 504 _(a), 504 _(b), .. . and 504 _(e), then straps 510 _(a), 510 _(b), . . . and 510 _(e) mayengage respective strap guiding members. For example, strap 510 _(a) mayengage strap guiding members 404 _(a) and 504 _(a), strap 510 _(b) mayengage strap guiding members 404 _(b) and 504 _(b), and so forth.

Depending on the type of straps used, ends of the straps may be coupledtogether with a connector or coupling device. FIG. 9 illustrates, inaccordance with an embodiment of the present invention, a couplingdevice 810 that may be used to connecting the two ends of a strap 510together. The coupling device 810 may be embodied in any suitable deviceincluding for example a metal strapping joint, a buckle or any othermechanism. In the specific example shown in FIG. 9, in this embodiment,the coupling device 810 is a metal strapping joint with a set of notches820 in order to securely fasten both ends of the strap together. Forexample, to couple the ends of the strap 510 together, this may be donewith a strapping sealer, such as a double notched strapping sealer, orany other suitable mechanical device. Furthermore, a band 850 may alsobe coupled around the coupling device 810 and the strap 810 to assist insecuring the coupling device in place.

FIG. 8E illustrates, in accordance with an embodiment of the presentinvention, after the compressed assembly of mattresses 790 containingthe stack of mattresses 302 has been secured or coupled with the straps510, raising the press plate 707 and removing the secured and compressedassembly of stacked mattresses 790 from the press 705. In non-limitingimplementations, the weight of the compressed assembly of mattresses 790may be kept between substantially 1500 pounds and substantially 2000pounds for ease of handling. The height of the compressed assembly ofmattresses 790 may be kept between substantially 47 inches andsubstantially 49 inches for ease of handling, loading, and unloading andfor safety considerations, including avoidance of a propensity fortipping off when handled with a forklift during storage on a highersection of a warehouse racking system.

The compressed assembly of stacked mattresses 790, as illustrated inFIG. 8E, should preferably not exceed approximately 8 feet in height ifto be shipped in a 40 foot Hi Cube container having an internal heightof about 8 feet and 10 inches. For conventional 40 foot containers and20 foot containers having an internal height of substantially 7 feet and10 inches, the compressed assembly of stacked mattresses 790 shouldpreferably not exceed approximately 7 feet in height. The space leftbetween the height of the compressed assembly of stacked mattresses 790and the internal height of the container may allow for ease of loadingand unloading. In addition, one or more compressed assemblies of stackedmattresses 790 may be stacked upon one another in a shipping container,provided preferably that the total height of the stacked compressedassemblies 790 does not exceed approximately 8 feet in the case of a HiCube container.

Weights and dimensions, presented above, have been given for the purposeof example only and practical implementations of the componentspresented in the present document may use other suitable measurementsthat may vary from those presented here.

Although in some of the embodiments discussed above, the upper and lowerpallets are constructed in the same or similar way, this is notnecessarily the case for some alternative embodiments of the invention.An example of such an alternative embodiment of an assembly of stackedmattresses is depicted in FIG. 10. As shown, the assembly 790′ includesa first pallet 1001, a second pallet 501 and a plurality of mattresses302 positioned between the first pallet 401 and the second pallet 501.In this example, the first pallet 1001 is a lower pallet and the secondpallet 501 is an upper pallet. The assembly 790′ is similar to theassembly of stacked mattresses 790 depicted in FIG. 1 with the lower (orfirst) pallet 1001 having a configuration that is different from thelower (or first) pallet 401 (shown in FIG. 1). More specifically, thelower pallet 1001 in the example depicted is constructed of an array ofwooden planks 1004 held in position by another array of woodencrosspieces or crossbars 1002 arranged orthogonally to the array ofwooden planks 1004. It will be readily appreciated that other variantsare possible and will become apparent to the person skilled in the artin view of the present description.

Certain additional elements that may be needed for operation of someembodiments have not been described or illustrated as they are assumedto be within the purview of those of ordinary skill in the art.Moreover, certain embodiments may be free of, may lack and/or mayfunction without any element that is not specifically disclosed herein.

Although various embodiments and examples have been presented, this wasfor the purpose of describing, but not limiting, the invention. Forexample, although in the embodiments discussed above relate toassemblies of stacked mattresses and method for preparing suchassemblies, similar assemblies (and method of preparing same) may alsobe considered for other types of bedding products such as for examplemattress covers, bedding foam, pillows, quilts, comforters. Variousother modifications and enhancements will become apparent to those ofordinary skill in the art. The invention is defined more particularly bythe appended claims.

1. An assembly of stacked mattresses comprising: a) a first pallet; b) asecond pallet; c) a plurality of mattresses positioned between the firstpallet and the second pallet; d) straps coupling the first pallet to thesecond pallet, the plurality of mattresses being in a compressed statebetween the first pallet and the second pallet and the strapsrestraining expansion of the plurality of mattresses; e) wherein thesecond pallet is comprised of: i) a supporting member; and ii) aplurality of elongated reinforcing members extending across thesupporting member, at least some elongated reinforcing members amongstthe plurality of elongated reinforcing members including respectivestrap guiding members, the strap guiding members extendinglongitudinally along the at least some elongated reinforcing members; f)wherein at least some of the straps engage respective ones of the strapguiding members of the plurality of elongated reinforcing members of thesecond pallet.
 2. The assembly of stacked mattresses defined in claim 1,wherein at least some of the strap guiding members are comprised ofhollow tubular portions and wherein at least some of the straps passthrough at least some of the hollow tubular portions.
 3. The assembly ofstacked mattresses defined in claim 1, wherein at least some of thestrap guiding members are comprised of U-shaped portions and wherein theat least some of the straps are positioned within at least some of theU-shaped portions, the U-shaped portions restraining movement of the atleast some straps relative to the supporting member of the secondpallet.
 4. The assembly of stacked mattresses defined in claim 1,wherein the strap guiding members are made at least in part of ametallic material.
 5. The assembly of stacked mattresses defined inclaim 1, wherein the supporting member of the second pallet is made atleast in part of a wood-based material.
 6. The assembly of stackedmattresses defined in claim 5, wherein the wood-based material is amedium-density fibreboard (MDF).
 7. The assembly of stacked mattressesdefined in claim 5, wherein the wood-based material is a plywoodmaterial.
 8. The assembly of stacked mattresses defined in claim 1,wherein the straps are made at least in part using a synthetic steelcomposite.
 9. The assembly of stacked mattresses defined in claim 1,wherein the supporting member of the second pallet has a surface areasubstantially similar to a surface area of an individual mattress in theplurality of mattresses.
 10. The assembly of stacked mattresses definedin claim 1, wherein the supporting member of the second pallet has asubstantially rectangular shape.
 11. The assembly of mattresses definedin claim 1, wherein said plurality of mattresses includes at least twomattresses.
 12. The assembly of stacked mattresses defined in claim 1,wherein the first pallet is comprised of: i) a supporting member; andii) a plurality of elongated reinforcing members extending across thesupporting member, at least some reinforcing members amongst theplurality of elongated reinforcing members of the first pallet includingrespective strap guiding members extending longitudinally along the atleast some elongated reinforcing members; wherein at least some strapsengage respective ones of the strap guiding members of the at least someelongated reinforcing members of the first pallet.
 13. The assembly ofstacked mattresses defined in claim 1, wherein the first pallet is abottom pallet and wherein the second pallet is a top pallet.
 14. Apallet for use in shipping bedding products, the pallet comprising: i) asupporting member; and ii) a plurality of elongated reinforcing membersextending across the supporting member, at least some reinforcingmembers amongst the plurality of elongated reinforcing members includingrespective strap guiding members, the strap guiding members extendinglongitudinally along the elongated reinforcing members.
 15. The palletdefined in claim 14, wherein at least some of the strap guiding membersare comprised of hollow tubular portions extending longitudinally alongthe elongated reinforcing members, said hollow tubular portions beingfor receiving therethrough straps.
 16. The pallet defined in claim 14,wherein at least some of the strap guiding members are comprised ofU-shaped portions extending longitudinally along the elongatedreinforcing members, said U-shaped portions being for receiving thereinstraps, said U-shaped portions being configured for restraining movementof straps positioned therein.
 17. The pallet defined in claim 14,wherein the strap guiding members are made at least in part of ametallic material.
 18. The pallet defined in claim 14, wherein thesupporting member of the pallet is made at least in part of a wood-basedmaterial.
 19. The pallet defined in claim 18, wherein the wood-basedmaterial is a medium-density fibreboard (MDF).
 20. The pallet defined inclaim 18, wherein the wood-based material is a plywood material.
 21. Thepallet defined in claim 14, wherein the supporting member has asubstantially rectangular shape.
 22. Use of the pallet defined in claim14, for shipping bedding products.
 23. Use of the pallet defined inclaim 14, for shipping mattresses.
 24. A method for preparing mattressesfor shipment, said method comprising: a) providing a first pallet and asecond pallet, wherein the second pallet is comprised of: i) asupporting member; and ii) a plurality of elongated reinforcing membersextending across the supporting member, at least some reinforcingmembers amongst the plurality of elongated reinforcing members includingrespective strap guiding members, the strap guiding members extendinglongitudinally along the at least some elongated reinforcing members; b)placing a plurality of mattresses on a surface of one of the firstpallet and the second pallet; c) placing the other one of the firstpallet and the second pallet on top of the plurality of mattresses; d)compressing the plurality of mattresses between the first pallet and thesecond pallet; and e) coupling the first pallet to the second palletusing straps, the straps restraining expansion of the compressedplurality of mattresses, at least some of the straps engaging respectiveones of the strap guiding members of the plurality of elongatedreinforcing members of the second pallet.
 25. The method defined inclaim 24, wherein at least some of the strap guiding members arecomprised of hollow tubular portions and wherein coupling the firstpallet to the second pallet includes passing at least some of the strapsthrough at least some of the hollow tubular portions.
 26. The methoddefined in claim 24, wherein at least some of the strap guiding membersare comprised of U-shaped portions and wherein coupling the first palletto the second pallet includes positioning at least some of the strapswithin at least some of the U-shaped portions, the U-shaped portionsrestraining movement of the at least some straps relative to thesupporting member of the second pallet.
 27. The method defined in claim24, wherein the strap guiding members are made at least in part of ametallic material.
 28. The method defined in claim 24, wherein thesupporting member of the second pallet is made at least in part of awood-based material.
 29. The method defined in claim 28, wherein thewood-based material is a medium-density fibreboard (MDF).
 30. The methoddefined in claim 28, wherein the wood-based material is a plywoodmaterial.
 31. The method defined in claim 24, wherein the straps aremade at least in part using a synthetic steel composite.
 32. The methoddefined in claim 24, wherein the supporting member of the second pallethas a surface area substantially similar to a surface area of anindividual mattress in the plurality of mattresses.
 33. The methoddefined in claim 24, wherein the supporting member of the second pallethas a substantially rectangular shape.
 34. The method defined in claim24, wherein said plurality of mattresses includes at least twomattresses.
 35. The method defined in claim 24, the method furthercomprising compressing individually the mattresses in the plurality ofmattresses prior to placing the plurality of mattresses on the firstpallet.
 36. The method as defined in claim 24, wherein the first palletis comprised of: i) a supporting member; and ii) a plurality ofelongated reinforcing members extending across the supporting member, atleast some reinforcing members amongst the plurality of elongatedreinforcing members of the first pallet including respective strapguiding members extending longitudinally along the at least someelongated reinforcing members; and wherein coupling the first pallet tothe second pallet includes engaging at least some of the straps withrespective ones of the strap guiding members of the at least someelongated reinforcing members of the first pallet.
 37. An assembly ofstacked mattresses prepared for shipment in accordance with the methoddefined in claim
 24. 38. An assembly of stacked mattresses comprising:a) a first pallet; b) a second pallet; c) a plurality of mattressespositioned between the first pallet and the second pallet; d) strapscoupling the first pallet to the second pallet, the plurality ofmattresses being in a compressed state between the first pallet and thesecond pallet and the straps restraining expansion of the plurality ofmattresses; e) wherein the second pallet is comprised of: i) asupporting member; and ii) a plurality of elongated grove membersextending across the supporting member; f) wherein at least some of thestraps engage respective ones of the elongated grove members of thesecond pallet.